Stator Assemblies For Three Phase Dynamoelectric Machines And Related Winding Methods

ABSTRACT

According to some aspects of the present disclosure, example stator assemblies for three phase dynamoelectric machines and related winding methods are disclosed. An example stator assembly generally includes a non-segmented stator core including a stator yoke and a plurality of teeth. The stator assembly also includes a plurality of coil portions electrically coupled in a delta winding pattern, and including a first coil portion extending around a first one of the plurality of teeth and a second coil portion extending around a second one of the plurality of teeth. The stator assembly further includes a plurality of connection portions including a first connection portion extending between the first coil portion and the second coil portion and electrically coupling the first coil portion and the second coil portion. The first coil portion, the second coil portion and the first connection portion are defined by a continuous length of winding wire.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.14/727,526 filed Jun. 1, 2015. The entire disclosure of the aboveapplication is incorporated herein by reference.

FIELD

The present disclosure relates to stator assemblies for three phasedynamoelectric machines and related winding methods.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art.

Stator assemblies for three phase dynamoelectric machines commonlyinclude a stator core having a yoke and multiple teeth extending fromthe yoke toward a central opening. Typically, a winding wire is woundaround a tooth to form a coil having two wire ends. This is repeated foreach of the multiple teeth to form multiple coils each having their ownwire ends. The different wire ends are then routed and bundled in groupsfor connecting to a power source. The power source may have differentphases requiring the different wire ends to be connected to the properphase.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

According to one aspect of the present disclosure, a stator assembly fora three phase dynamoelectric machine generally includes a non-segmentedstator core including a stator yoke and a plurality of teeth extendingfrom the stator yoke toward a central opening. The central openingextends from a first end of the stator core to a second end of thestator core opposite the first end. The plurality of teeth are spacedapart from one another and define a plurality of slots between theplurality of teeth for receiving windings of the stator assembly. Thestator assembly also includes a plurality of coil portions electricallycoupled in a delta winding pattern. The plurality of coil portionsincludes a first coil portion extending around a first one of theplurality of teeth and through slots on each side of the first one ofthe plurality of teeth, and a second coil portion extending around asecond one of the plurality of teeth and through slots on each side ofthe second one of the plurality of teeth. The stator assembly furtherincludes a plurality of connection portions including a first connectionportion extending between the first coil portion and the second coilportion and electrically coupling the first coil portion and the secondcoil portion. The first coil portion, the second coil portion and thefirst connection portion are defined by a continuous length of windingwire.

According to another aspect of the present disclosure, a stator assemblyfor a three phase dynamoelectric machine generally includes anon-segmented stator core including a stator yoke and a plurality ofteeth extending from the stator yoke toward a central opening. Thecentral opening extends from a first end of the stator core to a secondend of the stator core opposite the first end. The plurality of teethare spaced apart from one another and define a plurality of slotsbetween the plurality of teeth for receiving windings of the statorassembly. The stator assembly also includes a plurality of coil portionselectrically coupled in a delta winding pattern. The plurality of coilportions includes a first coil portion extending around a first one ofthe plurality of teeth and through slots on each side of the first oneof the plurality of teeth, and a second coil portion extending around asecond one of the plurality of teeth and through slots on each side ofthe second one of the plurality of teeth. The stator assembly furtherincludes a plurality of connection portions including a first connectionportion extending between the first coil portion and the second coilportion and electrically coupling the first coil portion and the secondcoil portion. The stator assembly also includes a first end cappositioned on the first end of the stator core, and a second end cappositioned on a second end of the stator core. The second end cap issubstantially identical in structure and configuration to the first endcap.

According to another aspect of the present disclosure a method ofwinding a stator assembly for a three phase dynamoelectric machine isdisclosed. The stator assembly includes a non-segmented stator coreincluding a stator yoke, a plurality of teeth extending from the statoryoke toward a central opening, and a plurality of coil portionselectrically coupled in a delta winding pattern. The plurality of coilportions includes a first coil portion and a second coil portion. Thecentral opening extends from a first end of the stator core to a secondend of the stator core opposite the first end. The plurality of teethare spaced apart from one another and define a plurality of slotsbetween the plurality of teeth for receiving windings of the statorassembly. The method includes winding a wire around a first one of theplurality of teeth to form the first coil portion about the first one ofthe plurality of teeth, and routing the wire from the first one of theplurality of teeth to a second one of the plurality of teeth to form aconnection portion between the first one of the plurality of teeth andthe second one of the plurality of teeth. The method also includeswinding the wire around a second one of the plurality of teeth to formthe second coil portion about the second one of the plurality of teeth,such that the first coil portion, the connection portion and the secondcoil portion are defined by a continuous length of wire.

Further aspects and areas of applicability will become apparent from thedescription provided herein. It should be understood that variousaspects of this disclosure may be implemented individually or incombination with one or more other aspects. It should also be understoodthat the description and specific examples herein are intended forpurposes of illustration only and are not intended to limit the scope ofthe present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of an example stator assembly according toone example embodiment of the present disclosure.

FIG. 2 is a diagram of an example delta winding connection pattern for astator assembly.

FIG. 3 is a perspective view of an end cap of FIG. 1.

FIG. 4A is a top view of the end cap of FIG. 3.

FIG. 4B is a bottom view of the end cap of FIG. 3.

FIG. 5 is a diagram of an example winding pattern for a stator assemblyhaving some lead portions wound outside of an end cap according to oneexample embodiment of the present disclosure.

FIG. 6 is a diagram of another example winding pattern for a statorassembly having four connection portion layers according to anotherexample embodiment of the present disclosure.

FIG. 7 is a diagram of another example winding pattern for a statorassembly having some lead portions wound inside of an end cap accordingto another example embodiment of the present disclosure.

FIG. 8 is a diagram of another example winding pattern for a statorassembly having six lead portion bundles according to another exampleembodiment of the present disclosure.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference tothe accompanying drawings.

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

A stator assembly for a three phase dynamoelectric machine according toone example embodiment of the present disclosure is illustrated in FIG.1, and indicated generally by the reference number 100. As shown in FIG.1, the stator assembly 100 includes a non-segmented stator core 102including a stator yoke 104 and a plurality of teeth 106 extending fromthe stator yoke toward a central opening 108. The central opening 108extends from one end 110 of the stator core 102 to another end 112 ofthe stator core. For example, the central opening 108 may extend from alead end 110 of the stator core 102 to an opposite lead end 112 of thestator core. The plurality of teeth 106 are spaced apart from oneanother and define a plurality of slots 114 between the plurality ofteeth for receiving windings of the stator assembly 100.

The stator assembly 100 also includes a plurality of coil portions 116each extending around one of the plurality of teeth 106 and throughslots 114 on each side of the tooth. The stator assembly 100 furtherincludes a plurality of connection portions 118 each extending betweentwo different coil portions 116 to electrically couple the two coilportions.

A continuous length of wire may define at least two coil portions 116and a connection portion 118 between the two coil portions. For example,a continuous length of wire may be wound about a first tooth 106, routedfrom the first tooth over to a second tooth, and wound about the secondtooth. Accordingly, a single continuous length of winding wire maydefine a first coil portion 116 about a first tooth, a connection 118portion from the first tooth to a second tooth, and a second coilportion about the second tooth, such that the winding wire defining thetwo coil portions and the connection portion does not have any breaks,cuts, interruptions, multiple segments, etc.

The three phase dynamoelectric machine may be any suitabledynamoelectric machine, including a motor, a generator, etc. Thedynamoelectric machine may include at least three terminals, which mayform first, second and third pairs of terminals for coupling to first,second and third phases of a three phase electric power source.

The multiple coil portions 116 of the stator assembly 100 may include afirst set of coil portions corresponding to a first phase of thedynamoelectric machine, a second set of coil portions corresponding to asecond phase of the dynamoelectric machine and a third set of coilportions corresponding to a third phase of the dynamoelectric machinefor coupling to a first phase, a second phase, and a third phase,respectively, of a three phase electric power source. Each phase mayinclude coil portion(s) coupled between a different pair of terminals ofthe dynamoelectric machine. For example, the coil portions 116 belongingto the first set of coil portions may be coupled between a first pair ofterminals of the dynamoelectric machine. The first pair of terminals maybe configured for coupling to a first phase of a three phase electricpower source, via any suitable coupling element(s), including leadportions, lead wire bundles, terminal connectors, etc. The second set ofcoil portions 116 may be coupled between a second pair of terminals ofthe dynamo electric machine (which may include one terminal of the firstpair of terminals), and the second pair of terminals may be configuredfor coupling to a second phase of the three phase electric power source.Similarly, the third set of coil portions may be coupled between a thirdpair of terminals (which may include one terminal from the first pairand one terminal from the second pair), and the third pair of terminalsmay be configured for coupling to a third phase of the three phaseelectric power source. Accordingly, the first set of coil portions 116may all be energized with the same power phase, the second set of coilportions may all be energized with a same power phase that is differentfrom the first set of coil portions, and the third set of coil portionsmay all be energized with a same power phase that is different from thefirst set of coil portions and the second set of coil portions.

The stator assembly 100 may include a total of nine teeth 106 and atotal of nine coil portions 116. Each of the nine coil portions 116 maybe wound about a different one of the nine teeth and through slots 114on each side of said different one of the nine teeth. Other embodimentsmay include more or less teeth 106 and more or less coil portions 116(e.g., three teeth and three coil portions, six teeth and six coilportions, twelve teeth and twelve coil portions, etc.). The number ofcoil portions 116 may or may not correspond to the number of teeth 106of the stator assembly 100, and each tooth 106 may include no coilportion, a single coil portion, more than one coil portion, etc.

The coil portions 116 may be electrically coupled in a delta windingpattern. An example delta winding pattern diagram 200 is shown in FIG.2. The delta winding pattern 200 includes three different phaseconnection wires (201, 203, 205) for connecting to different phases of athree phase electric power source (not shown). Each coil portion 216belongs to one of three different sets of coil portions (Phase A, PhaseB, Phase C) and is coupled to a respective phases of the three phaseelectric power source via the phase connection wires 201, 203, 205.

Referring back to FIG. 1, adjacent coil portions 116 may belong todifferent ones of the sets of coil portions described above. Forexample, a coil portion 116 belonging to the first set of coil portionsthat is configured for coupling to a first phase of the three phaseelectric power source may be adjacent a coil portion belonging to thesecond set of coil portions on one side, and also adjacent a coilportion belonging to the third set of coil portions on the other side.The coil portions 116 may alternate to provide an even distribution ofeach set of coils around the stator assembly 100. For example, the coilportions may be ordered sequentially around the stator core 102 (e.g.,in an order of a first phase coil portion, then a second phase coilportion, then a third phase coil portion, then starting over at a firstphase coil portion, etc.).

Each connection portion 118 may extend between two coil portions 116 andelectrically couple the two coil portions. For example, the connectionportion 118 may include a length of winding wire connecting two coilportions. The connection portion 118 may be continuous, may be cut intoone or more segments, etc. The connection portion 118 may be anintermediate portion of a continuous length of wire defining two coilportions 116 and the connection portion 118.

The connection portion 118 may include one or more lead portions 120.For example, the connection portion 118 may include a portion of windingwire that can be coupled to a phase connection wire of a three phaseelectric power source. The lead portion 120 may be a part of theconnection portion 118 that extends out from the stator core 102 (e.g.,via a bend in the winding wire, etc.) to be connected to a power source.Accordingly, a continuous length of wire may define a first coil portion116, a connection portion 118 including a lead portion 120, and a secondcoil portion.

Each lead portion 120 of the plurality of connection portions 118 may bepositioned in one of a first, second or third lead bundle for couplingto a first phase, a second phase, or a third phase, respectively, of athree phase electric power source. For example, the stator assembly 100may include multiple lead portions 120 (e.g., six lead portions, ninelead portions, twelve lead portions, etc.). The multiple lead portions120 may be positioned in bundles with other lead portions that areconfigured to connect to the same phase of a three phase electric powersource. Once the lead portions 120 are bundled, each bundle can becoupled to its respective phase of the three phase power source.

The lead portions 120 of the stator assembly 100 may be routed throughless than all of the slots 114 of the stator assembly, such that someslots may not contain any lead portions. Accordingly, the lead portions120 may be grouped so that the lead portions are routed through only asubset of all of the slots 114. Lead portions 120 corresponding to thesame phase of a three phase electric power supply may be routed throughthe same slots 114. Routing lead portions 120 through less than all ofthe slots 114 may provide one or more advantages, including reducing theneed to manually route and couple lead portions from different slots,reducing the complexity of guiding the lead portions about the lead endof the stator core 102, etc.

In some embodiments, the lead portions 120 may be routed through no morethan six slots 114 of the stator assembly 100. This may create sixbundles of lead portions 120, which may require regrouping and routingof some of the lead portions. In some embodiments, the lead portions 120may be routed through no more than four of the slots 114 of the statorassembly 100. This may reduce the amount of regrouping and routing oflead portions 120 that may be required when the lead portions extendfrom more than four slots. The regrouping and routing may includecutting one or more wires to combine the lead portions into three leadbundles.

In some embodiments, the lead portions 120 may be routed through no morethan three of the slots 114 of the stator assembly 100. Routing the leadportions 120 through no more than three slots 114 may reduce the need tomanually route and couple lead portions from different slots, as alllead portions may be properly grouped in three lead bundles. In otherembodiments, the lead portions 120 may be routed through more or less(including none or all) or the slots 114 of the stator assembly 100.

The stator assembly 100 may include an end cap 122 positioned on an endof the stator core 102. The end cap 122 may be positioned at a lead end110 of the stator core 102, an opposite lead end of the stator core 112,etc.

An example end cap 122 is illustrated in FIGS. 3, 4A and 4B. The end cap122 includes a yoke portion 125 which corresponds to a circumference ofthe yoke 104 of the stator core 102. The end cap 122 also includes toothportions 127 which correspond to the teeth 106 of the stator core.

The end cap 122 may include a wall 129 extending from the yoke portion125. The wall 129 may be discontinuous to allow routing of wire thoughand around the end cap 122. The wall 129 may keep the connectionportions 118 of the wire tight, provide some tension, etc.

The end cap 122 includes a plurality of guides 124 for separatingconnection portions 118 corresponding to different phases to preventshorting between the connection portions corresponding to the differentphases. The guides 124 may be any suitable elements for separating theconnection portions 118, including ribs, tabs, walls, etc.

The guides 124 may define routing paths 126 (e.g., trenches, channels,tracks, etc.) in which the different connection portions 118 arepositioned. For example, as shown in FIG. 1, connection portions 118corresponding to a first phase may be positioned on one side of a guide124 in a first routing path 126, while connection portions correspondingto a second phase may be positioned on another side of the guide in asecond routing path. Accordingly, the connection portions 118 indifferent routing paths 126 may not contact each other and therefore maynot short one another as the connection portions are routed betweendifferent coil portions 116.

A routing path 126 may be any suitable path capable of separatingportions of winding wire. As shown in FIG. 1, the end cap 122 may extendfrom an end of the stator core 102 parallel to a longitudinal directionof the teeth 106. The outer wall 129 of the end cap 122 includesmultiple guides 124 which separate the outer wall of the end cap 122into multiple routing paths 126. The routing paths 126 are portions ofthe end cap outer wall 129 that provide a surface along which theconnection portions 118 are positioned. In the embodiment of FIG. 1, therouting paths 126 are flush with the outer wall surface of the end cap122, and the guides 124 are only located intermittently along portionsof the sides of the routing paths. Thus, the guides 124 may not fullydefine walls of a routing path 126. A routing path 126 may only haveguides 124 on one side of the routing path. A routing path 126 may beflush with the surface of the wall 129 of the end cap 122. Accordingly,a routing path 126 may include sides defined at least partially by oneor more guides 124 on at least one side of the routing path 126, and mayhave a surface defined by the wall 129 of the end cap 122. In otherembodiments, the guides 124 may fully define a wall of a routing path126 on a side of the routing path, the guides 124 may define walls of arouting path on both sides of the routing path, the routing path may belowered with respect to the end cap wall surface, the routing path mayinclude ruts, impressions, etc. for positioning the winding wire, etc.

The multiple guides 124 may define any suitable number of routing paths126. For example, the multiple guides 124 may define no more than fourrouting paths 126 for routing the connection portions 118, no more thanthree routing paths for routing the connection portions, etc. The numberof routing paths 126 may correspond to the number of phases thatdifferent connection portions 118 can connect to. For example, the endcap 122 may include three routing paths 126 when the stator assembly 100includes connection portions 118 configured to connect to one of threedifferent phases of a three phase electric power source. The number ofrouting paths 126 may be a minimum number of routing paths required toroute the connection portions 118 without having any contact betweenconnection portions corresponding to different phases. Other embodimentsmay include more or less (or none) routing paths 126.

The end cap 122 can be made out of any suitable material(s), includingplastic, etc. The end cap 122 may be non-conductive to prevent shortingof different connection portions 118.

The stator assembly 100 may include two end caps 122, which may bepositioned at opposite ends of the stator core 102. For example, one endcap may be positioned at a lead end of the stator core 102, while asecond end cap is positioned at an opposite lead end of the stator core102. The end cap at the opposite lead end of the stator core 102 may beused to route the connection portions 118 of the winding wire as thewire is routed from one coil portion to another coil portion. The endcap 124 at the lead end of the stator core 102 may be configured toroute at least some of the lead portions 120 into lead bundles, guiderouting of the lead portions as they are grouped into lead bundles,guide the lead portions out of the stator core for connection to a threephase electric power source, etc.

The end caps 122 at both ends of the stator core 102 may havesubstantially similar structure and configuration. For example, both endcaps 122 may be identical, such that the end caps are interchangeable ateither end. This may provide one or more advantages, including reducingthe need to produce and store multiple end cap parts having differentdesigns, reducing the need to manage proper selection and placement ofdifferent end cap designs at different locations on the stator core 102,etc.

The end caps 122 may not be symmetrical. Accordingly, some points of theend caps 122 may align at each end of the stator core 102 (e.g., twelveo'clock and six o'clock points, etc.), while other end cap features maybe positioned at different locations at each end of the stator core. Theend caps 122 may be designed such that some features correspond to therouting of the connection portions 118 at an opposite lead end of thestator core 102, while other features of the end cap correspond to therouting of the lead portions 120 at the lead end of the stator core.

The end cap 122 may include one or more locating tabs 123. The end cap122 shown in FIG. 3 includes 4 locating tabs 123. Other embodiments mayinclude more or less (or none) locating tabs 123. The locating tabs 123may have different sizes, different shapes, etc., which may provideclocking such that the end cap 122 has a correct orientation withrespect to the stator core 102. The locating tabs may cooperate withgrooves in the stator core 102 (e.g., grooves in laminations of thestator core, etc.). The locating tabs 123 may provide alignment of theend cap 122, and may prevent rotation of the end cap.

The stator assembly 100 may include one or more continuous lengths ofwinding wire. For example, all coil portions 116 and connection portions118 may be defined by one continuous length of winding wire. Onecontinuous length of winding wire may be wound about all of the teeth106 of the stator assembly 100.

In some embodiments, the stator assembly 100 may include multiplecontinuous lengths of winding wire (i.e., multiple continuous windingwire segments). For example, a continuous length of wire may be woundabout all teeth 106 of the stator assembly 100, and then cut at one ormore points to form wire segments. Each cut may create two additionalwire ends and one additional wire segment. In some embodiments, all coilportions 116 and connection portions 118 may be defined by no more thanfour continuous lengths of winding wire (e.g., four wire segments havinga total of eight wire ends formed by three cuts of one continuous lengthof wire). Some embodiments may include all coil portions 116 andconnection portions defined by no more than three continuous lengths ofwinding wire (e.g., three wire segments having a total of six wire endsformed by two cuts of one continuous length of wire). Some embodimentsmay include all coil portions 116 and connection portions defined by nomore than two continuous lengths of winding wire (e.g., two wiresegments having a total of four wire ends formed by one cut of onecontinuous length of wire). In other embodiments, more or lesscontinuous lengths of winding wire may define the coil portions 116 andconnection portions 118. The continuous lengths of winding wire may beformed by cutting winding wire, winding multiple wires separately, etc.

FIG. 5 illustrates a winding pattern 300 for a stator assembly, whichmay be similar to the stator assembly 100 of FIG. 1. The winding pattern300 includes a continuous length of wire wound about all nine teeth 306of the stator assembly. The arrows of the length of wire indicate adirection of winding of the wire, from a start point of the wire to anend point of the wire.

The winding pattern 300 includes coil portions 316 about each tooth 306of the stator assembly. Although the winding pattern 300 illustratesonly one turn about each tooth 306, any suitable number of turns (e.g.,70 turns, 80 turns, etc.) may be used.

The winding pattern 300 includes connection portions 318 between coilportions 316. The connection portions 316 are separated into threelayers. These 3 layers may correspond to different routing paths 126 ofthe end cap 122 illustrated in FIG. 1 (not shown in FIG. 5). Forexample, the top layer of the connection portions 318 in the windingpattern 300 may be positioned in a routing path 126 of the end cap 122that is furthest from an end 112 of the stator core, the middle layer ofconnection portions 318 may be positioned in the middle routing path ofthe end cap, and the bottom layer of connection portions 318 may bepositioned in the routing path closest to the end of the stator core.

Although the connection portion 318 cross over one another at somelocations in the winding pattern 300, connection portions 318 connectingto different phases of a three phase electric power source may beseparated from contacting one another by the end cap 122. For example,when connection portions 318 from different layers are shown asoverlapping in winding pattern 300, the end cap 122 may instead routethe connection portions 318 on different sides of the end cap at thosepoints.

Each connection portion 318 also includes a lead portion 320 whichextends out from one of the slots 314 between the teeth 306. Forexample, each connection portion 318 begins from one coil portion 316about a first tooth, defines a lead portion which extends though one ofthe slots 314, and then extends to another tooth to from another coilportion.

The lead portions 120 may be bundled together to form lead bundles 328.For example, winding pattern 300 includes three lead bundles 328. Theselead bundles may include only lead portions 320 corresponding to thesame phase of a three phase electric power source. Once bundled, thelead bundles 328 can be connected to the power source.

As shown in FIG. 5, the winding pattern 300 includes lead portions 320extending from four of the nine slots 314 of the stator assembly. Eachlead bundle includes lead portions 320 extending from a different slot314. For example, one lead bundle 328 includes five lead portions 320extending from the slot 314 between the ninth tooth 306 and the firsttooth, and a sixth lead portion extending from the slot between thefirst tooth and the second tooth. The sixth lead portion 320 belongingto this bundle may be routed outside an end cap to the other leadportion in the same bundle. For example, the stator assembly may includeend caps 122 on both sides as shown in FIG. 1 (not shown in FIG. 5). Theconnection portions 318 are routed in layers through an end cap 122 atone end of the stator core 102, while some lead portions are routedaround an end cap at the other end of the stator core. The lead portions320 being routed horizontally at a position away from the teeth 306indicates those lead portions are routed outside the end cap 122.

The lead portions 320 which are routed from one slot 314 over to therest of the lead portion in the same bundle may be cut and repositionedin the bundle for easier bundling. For example, a winding machine maywind the wire through the stator assembly according to the windingpattern 300 of FIG. 5, and then a technician, machine, etc. may cut thelead portions 320 at locations 330 and reposition those cut lead potionsin the respective bundle. This may make the winding process moreefficient as the machine may more easily wind some lead portion 320 indifferent slots 314 and outside the end cap 122 at the lead end of thestator core 102. Accordingly, this embodiment may include fourcontinuous lengths of wire that define all coil portions 316 andconnection portions 318.

In some embodiments, the winding wire may be wound through the teeth ina winding pattern to increase slot fill in the slots 314. The windingwire may be wound to maximize the slot fill.

FIG. 6 illustrates another example winding pattern 400, which has somesimilarities to the winding pattern 300 of FIG. 5. Winding pattern 400includes coil portions 416, connection portions 418, lead portions 420,and lead bundles 428.

The connection portions 418 in winding pattern 400 are divided into 4layers (comparted to only 3 layers in winding pattern 300 of FIG. 5).Accordingly, an end cap design would require four routing paths 126 toaccommodate the 4 layers of connection portions 418 in winding pattern400.

As shown in FIG. 6, the winding pattern 400 includes lead portions 420extending from only three slots 414 (as opposed to four slots 314 inFIG. 5). All lead portions 420 belonging to the same bundle 428 extendfrom the same slot 414. For example, all lead portions 420 belonging tothe first bundle 428 extend from the slot 414 between the first tooth406 and the second tooth. This is in contrast to the winding pattern 300in which lead portions 320 belonging to the same bundle 328 can extendfrom different slots 314.

Winding pattern 400 includes a single continuous length of wire thatdefines all coil portions 418, connection portions 418 and lead portions420.

FIG. 7 illustrates another example winding pattern 500, which has somesimilarities to the winding pattern 300 of FIG. 5. Winding pattern 500includes coil portions 516, connection portions 518, lead portions 520,and lead bundles 528.

Each lead bundle 528 includes lead portions 520 which extend fromdifferent slots 514 (similar to winding pattern 300 of FIG. 5), but thelead portions 520 belonging to the same lead bundle 520 are routedtogether on the inside of the end cap 122, as opposed to the outside ofthe end cap in winding pattern 300 of FIG. 5. This is indicated by thelead portions 520 being routed horizontally from one slot to another ata location very close to the end of the teeth 506.

The winding pattern 500 includes lead portions 520 extending from fourof the nine slots 514. Because the lead portions 520 are routed torespective lead bundles 528 on the inside of the end cap 122, there maybe no need to cut the winding wire. Accordingly, all coil portions 516,connection portions 518 and lead portions 520 may be defined by a singlecontinuous length of wire.

FIG. 8 illustrates another example winding pattern 600 including coilportions 616, connection portions 618, lead portions 620, and leadbundles 628. Winding pattern 600 includes six lead bundles 628, asopposed to the three lead bundles of winding patterns 300, 400 and 500.Accordingly, the winding pattern 600 includes lead portions 620extending from six of the nine slots 614.

The lead bundles 628 may have to be manually combined to form only threelead bundles for connecting to three phases of a three phase electricpower source. The winding pattern 600 may not require any cutting of thewinding wire. Accordingly, the winding pattern 600 man include a singlecontinuous length of wire defining all coil portions 616, connectionportions 618 and lead portions 620.

The example stator assembly 100 of FIG. 1 may include any windingpattern described herein (e.g., winding patterns 300, 400, 500 and 600),or may include any other suitable winding pattern, and the windingpatterns described herein may be implemented in the example statorassemblies described herein or any other suitable stator assemblies.

The stator core 102 may be any suitable stator core having any suitablesize and shape. In some embodiments, the stator may have a frame size of63, a frame size of 70, etc. The stator assembly 100 may be used in anysuitable implementation, including variable speed motors, fixed speedmotors, etc.

The coil portions may be any suitable coils wound about the teeth 106 ofthe stator core 102. In some embodiments, the coil potions 116 may eachinclude the same number of turns. The coil portions 116 may each includebetween about 70 to 80 turns. Other embodiments may include more or lessturns per coil portion, and different coil portions may includedifferent numbers of turns.

The winding wire may include any suitable wire, which may comprise anysuitable conductor material(s). For example, the winding wire mayinclude copper, aluminum, a compound alloy, etc.

The winding wire may be any suitable size. In some embodiments, thewinding wire may have a wire gauge in the range of 18 to 19 AWG. Thewinding wire may preferably have a wire gauge of 18.5 AWG. Otherembodiments may include winding wire having a different wire gauge.

The end cap 122 may allow for the winding wire to not include any sleevecovering any connection portions of the winding wire. For example, theguides 124 of the end cap 122 may separate connection portions 118corresponding to different phases of a three phase electric powersource, such that no sleeve is needed to cover the connection portionsas they are routed between coil portions. Although a sleeve is notrequired, one or more sleeves can still be used if desired.

In some embodiments, the stator assembly 100 may be assembled into acompressor. Accordingly, a compressor may include the stator assembly100, which may be combined with a rotor, etc.

According to another example embodiment, a method of winding a statorassembly for a three phase dynamoelectric machine is disclosed. Themethod may be implemented with any example stator assemblies describedherein, or with other stator assemblies, and may form any of the windingpatterns described herein (e.g., winding pattern 300, 400, 500, and 600)or any other suitable winding patterns.

The example method includes winding a wire around a first one of aplurality of teeth of a stator core to form a first coil portion aboutthe first tooth, routing the wire from the first one of the plurality ofteeth to a second one of the plurality of teeth to form a connectionportion between the first tooth and the second tooth, and winding thewire around the second tooth to form a second coil portion about thesecond tooth, such that the first coil portion, the connection portionand the second coil portion are defined by a continuous length of wire.

Winding the wire according to this example method creates two coilportions and a connection portion between the two coil portions which isdefined by a continuous length of wire, such that coil portions aboutdifferent teeth are connected by a continuous length of wire. The methodmay also include winding the continuous wire around the remaining teethto form coils about each of the remaining teeth, such that all coilportions are defined by a continuous length of winding wire.

Winding the wire around the remaining teeth may include routing the wirebetween coil portions in a delta connection winding pattern to definelead portions of the winding wire positioned in one of a first, secondor third lead bundle for coupling to a first phase, a second phase, or athird phase, respectively, of a three phase electric power source. Forexample, the wire may be wound to form a delta connection windingpattern in which each coil portion corresponds to one of the threephases of the dynamoelectric machine. When routing the wire from onecoil portion to another, a lead portion may be defined (e.g., by routingthe wire out of the stator core and back into the stator core, etc.).Each lead portion may be routed to form a lead bundle with other leadportions that correspond to the same phase of the electric power source.

The example method may include cutting at least one lead portion todefine two wire ends. The two wire ends may be bundled together withother lead portions that correspond to the same phase. Accordingly, alead portion may be cut and then bundled together to form a lead bundle.The cutting of one or more lead portions may be done after a continuouslength of wire has been wound about all of the multiple teeth of thestator core. The cutting of one or more lead portions may allow foreasier bundling of the lead portions for connection to phases of thethree phase electric power source.

The example method may be implemented using a winding machine toautomatically wind the wire about the multiple teeth of the stator core.For example, a winding machine may use a single needle to thread, guide,route, etc. a continuous length of winding wire around the multipleteeth, and from one tooth to another tooth. The winding wire machine maywind the wire in a delta winding pattern with lead portions that extendout of the stator core for coupling to different phases of a three phaseelectric power source. The winding wire machine may route the wire fromone tooth to another via an end cap, and may separate connectionportions into respective routing paths of the end cap based on differentphases of connection portions.

The winding machine may be any suitable machine configured to wirestator assemblies. The winding machine may be a single needle windingmachine. For example, the winding machine may use a single needle towind a single continuous length of winding wire about all teeth of astator assembly. Other embodiments may use more than one winding needle.

The winding machine may move the single needle vertically and move thestator assembly horizontally to wind the wire about the multiple teethof the stator assembly. Other embodiments may move the needle and statorassembly in other suitable directions.

The example method may also include assembling the stator assembly intoa compressor after winding the wire around the plurality of teeth. Oncethe stator assembly is wound, the stator assembly may be assembled intoa compressor, which may include assembling the stator assembly withother suitable compressor components, a rotor, etc.

The winding machine may use any suitable winding pattern for winding thestator assembly. For example, FIG. 5 illustrates an example windingpattern in which a method of winding the wire may include routing thewire from the first end of the stator assembly to the second end of thestator assembly through a slot between the second tooth (indicated bytooth #2 in FIG. 5) and the third tooth (indicated by tooth #3 in FIG.5) to form a lead portion belonging to a first lead bundle, routing thewire along the second end cap to the eighth tooth, and winding the wireabout the eighth tooth to form a coil portion about the eighth tooth,routing the wire along the second end cap from the eighth tooth to aslot between the first tooth and the second tooth, routing the wirethrough the slot between the first tooth and the second tooth twice toform another lead portion belonging to a second lead bundle, and routingthe wire along the second end cap to the seventh tooth, to form aconnection portion between the eighth tooth and the seventh tooth,winding the wire about the seventh tooth to form a coil portion aboutthe seventh tooth, routing the wire along the second end cap from theseventh tooth to a slot between the ninth tooth and the first tooth,routing the wire through the slot between the ninth tooth and the firsttooth twice to form another lead portion belonging to a third leadbundle, routing the wire along the second end cap to the sixth tooth,winding the wire about the sixth tooth, routing the wire along thesecond end cap from the sixth tooth to the slot between the second toothand the third tooth, routing the wire through the slot between thesecond tooth and the third tooth twice to form another lead portionbelonging to the first lead bundle, routing the wire along the secondend cap to the fifth tooth, winding the wire about the fifth tooth,routing the wire along the second end cap from the fifth tooth to theslot between the first tooth and the second tooth, routing the wirethrough the slot between the first tooth and the second tooth twice toform another lead potion belonging to the second lead bundle, routingthe wire along the second end cap to the fourth tooth, winding the wireabout the fourth tooth, routing the wire along the second end cap fromthe fourth tooth to the slot between the ninth tooth and the firsttooth, routing the wire through the slot between the ninth tooth and thefirst tooth twice to form another lead portion belonging to the thirdlead bundle, routing the wire along the second end cap to the thirdtooth, winding the wire about the third tooth, routing the wire alongthe outside of the first end cap from the third tooth to the secondtooth to form another lead portion belonging to the first lead bundle,winding the wire about the second tooth, routing the wire along theoutside of the first end cap from the second tooth to the first tooth toform another lead portion belonging to the second lead bundle, windingthe wire about the first tooth, routing the wire outside of the firstend cap from the first tooth to the ninth tooth to form another leadportion belonging to the third lead bundle, winding the wire about theninth tooth, and routing the wire along the first end cap from the ninthtooth to the slot between the second tooth and the third tooth to formanother lead portion belonging to the first lead bundle.

As another example, FIG. 6 illustrates an example winding pattern inwhich a method for winding the stator assembly may include routing thewire from the first end of the stator assembly to the second end of thestator assembly through a slot between the third tooth and the fourthtooth to form a lead portion belonging to a first lead bundle, routingthe wire along the second end cap to the ninth tooth, and winding thewire about the ninth tooth to form a coil portion about the ninth tooth,routing the wire along the second end cap from the ninth tooth to a slotbetween the second tooth and the third tooth, routing the wire throughthe slot between the second tooth and the third tooth twice to formanother lead portion belonging to a second lead bundle, and routing thewire along the second end cap to the eight tooth, to form a connectionportion between the ninth tooth and the eighth tooth, winding the wireabout the eighth tooth to form a coil portion about the eighth tooth,routing the wire along the second end cap from the eighth tooth to aslot between the first tooth and the second tooth, routing the wirethrough the slot between the first tooth and the second tooth twice toform another lead portion belonging to a third lead bundle, routing thewire along the second end cap to the seventh tooth, winding the wireabout the seventh tooth, routing the wire along the second end cap fromthe seventh tooth to the slot between the third tooth and the fourthtooth, routing the wire through the slot between the third tooth and thefourth tooth twice to form another lead portion belonging to the firstlead bundle, routing the wire along the second end cap to the sixthtooth, winding the wire about the sixth tooth, routing the wire alongthe second end cap from the sixth tooth to the slot between the secondtooth and the third tooth, routing the wire through the slot between thesecond tooth and the third tooth twice to form another lead potionbelonging to the second lead bundle, routing the wire along the secondend cap to the fifth tooth, winding the wire about the fifth tooth,routing the wire along the second end cap from the fifth tooth to theslot between the first tooth and the second tooth, routing the wirethrough the slot between the first tooth and the second tooth twice toform another lead portion belonging to the third lead bundle, routingthe wire along the second end cap to the fourth tooth, winding the wireabout the fourth tooth, routing the wire along the second end cap fromthe fourth tooth to a slot between the third tooth and the fourth tooth,routing the wire through the slot between the third tooth and the fourthtooth once to form another lead portion belonging to the first leadbundle, winding the wire about the third tooth, routing the wire alongthe second end cap from the third tooth to the second tooth, routing thewire trough the slot between the second tooth and the third tooth onceto form another lead portion belonging to the second lead bundle,winding the wire about the second tooth, routing the wire along thesecond end cap from the second tooth to the slot between the first toothand the second tooth, routing the wire through the slot between thefirst tooth and the second tooth once to form another lead portionbelonging to the third lead bundle, winding the wire about the firsttooth, and routing the wire along the first end cap from the first toothto the slot between the third tooth and the fourth tooth to form anotherlead portion belonging to the first lead bundle.

As another example, FIG. 7 illustrates an example winding pattern inwhich a method for winding the stator assembly may include routing thewire from the first end of the stator assembly to the second end of thestator assembly through a slot between the second tooth and the thirdtooth to form a lead portion belonging to a first lead bundle, routingthe wire along the second end cap to the eighth tooth, and winding thewire about the eighth tooth to form a coil portion about the eighthtooth, routing the wire along the second end cap from the eighth toothto a slot between the first tooth and the second tooth, routing the wirethrough the slot between the first tooth and the second tooth twice toform another lead portion belonging to a second lead bundle, and routingthe wire along the second end cap to the seventh tooth, to form aconnection portion between the eighth tooth and the seventh tooth,winding the wire about the seventh tooth to form a coil portion aboutthe seventh tooth, routing the wire along the second end cap from theseventh tooth to a slot between the ninth tooth and the first tooth,routing the wire through the slot between the ninth tooth and the firsttooth twice to form another lead portion belonging to a third leadbundle, routing the wire along the second end cap to the sixth tooth,winding the wire about the sixth tooth, routing the wire along thesecond end cap from the sixth tooth to the slot between the second toothand the third tooth, routing the wire through the slot between thesecond tooth and the third tooth twice to form another lead portionbelonging to the first lead bundle, routing the wire along the secondend cap to the fifth tooth, winding the wire about the fifth tooth,routing the wire along the second end cap from the fifth tooth to theslot between the first tooth and the second tooth, routing the wirethrough the slot between the first tooth and the second tooth twice toform another lead potion belonging to the second lead bundle, routingthe wire along the second end cap to the fourth tooth, winding the wireabout the fourth tooth, routing the wire along the second end cap fromthe fourth tooth to the slot between the ninth tooth and the firsttooth, routing the wire through the slot between the ninth tooth and thefirst tooth twice to form another lead portion belonging to the thirdlead bundle, routing the wire along the second end cap to the thirdtooth, winding the wire about the third tooth, routing the wire alongthe inside of the first end cap from the third tooth to the second toothto form another lead portion belonging to the first lead bundle, windingthe wire about the second tooth, routing the wire along the inside ofthe first end cap from the second tooth to the first tooth to formanother lead portion belonging to the second lead bundle, winding thewire about the first tooth, routing the wire inside of the first end capfrom the first tooth to the ninth tooth to form another lead portionbelonging to the third lead bundle, winding the wire about the ninthtooth, and routing the wire along the first end cap from the ninth toothto the slot between the second tooth and the third tooth to form anotherlead portion belonging to the first lead bundle.

As another example, FIG. 8 illustrates an example winding pattern inwhich a method for winding the stator assembly may include routing thewire from the first end of the stator assembly to the second end of thestator assembly through a slot between the third tooth and the fourthtooth to form a lead portion, routing the wire along the second end capto the ninth tooth, and winding the wire about the ninth tooth to form acoil portion about the ninth tooth, routing the wire along the secondend cap from the ninth tooth to a slot between the second tooth and thethird tooth, routing the wire through the slot between the second toothand the third tooth twice to form another lead portion, and routing thewire along the second end cap to the eighth tooth, to form a connectionportion between the ninth tooth and the eighth tooth, winding the wireabout the eighth tooth to form a coil portion about the eighth tooth,routing the wire along the second end cap from the eighth tooth to aslot between the first tooth and the second tooth, routing the wirethrough the slot between the first tooth and the second tooth twice toform another lead portion, routing the wire along the second end cap tothe seventh tooth, winding the wire about the seventh tooth, routing thewire along the second end cap from the seventh tooth to the slot betweenthe sixth tooth and the seventh tooth, routing the wire through the slotbetween the sixth tooth and the seventh tooth once to form another leadportion, winding the wire about the sixth tooth, routing the wire alongthe second end cap from the sixth tooth to the slot between the fifthtooth and the sixth tooth, routing the wire through the slot between thefifth tooth and the sixth tooth once to form another lead potion,winding the wire about the fifth tooth, routing the wire along thesecond end cap from the fifth tooth to the slot between the fourth toothand the fifth tooth, routing the wire through the slot between thefourth tooth and the fifth tooth once to form another lead portion,winding the wire about the fourth tooth, routing the wire along thesecond end cap from the fourth tooth to the slot between the third toothand the fourth tooth, routing the wire through the slot between thethird tooth and the fourth tooth to form another lead portion, windingthe wire about the third tooth, routing the wire along the second endcap from the third tooth to slot between the second tooth and the thirdtooth, routing the wire through the slot between the second tooth andthe third tooth once to form another lead portion, winding the wireabout the second tooth, routing the wire along the second end cap fromthe second tooth to the slot between the first tooth and the secondtooth, routing the wire through the slot between the first and secondtooth once to form another lead portion, winding the wire about thefirst tooth, and routing the wire along the first end cap from the firsttooth to the slot between the third tooth and the forth tooth to formanother lead portion.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

What is claimed is:
 1. A method of winding a stator assembly for a threephase dynamoelectric machine, the stator assembly including anon-segmented stator core including a stator yoke, a plurality of teethextending from the stator yoke toward a central opening, and a pluralityof coil portions electrically coupled in a delta winding pattern, theplurality of coil portions including a first coil portion and a secondcoil portion, the central opening extending from a first end of thestator core to a second end of the stator core opposite the first end,the plurality of teeth spaced apart from one another and defining aplurality of slots between the plurality of teeth for receiving windingsof the stator assembly, the method comprising: winding a wire around afirst one of the plurality of teeth to form the first coil portion aboutthe first one of the plurality of teeth; routing the wire from the firstone of the plurality of teeth to a second one of the plurality of teethto form a connection portion between the first one of the plurality ofteeth and the second one of the plurality of teeth; and winding the wirearound the second one of the plurality of teeth to form the second coilportion about the second one of the plurality of teeth such that thefirst coil portion, the connection portion and the second coil portionare defined by a continuous length of wire.
 2. The method of claim 1,further comprising: winding the continuous length of wire aroundremaining teeth of the plurality of teeth to form coil potions abouteach of the remaining teeth of the plurality of teeth, such that allcoil portions are defined by a continuous length of wire.
 3. The methodof claim 2, wherein winding the wire around the remaining teeth of theplurality of teeth includes routing the wire between coil portions in adelta connection winding pattern such that each coil portion correspondsto one of three phases of the dynamoelectric machine.
 4. The method ofclaim 1, wherein each connection portion includes a lead portion, themethod further comprising cutting at least one lead portion to definetwo wire ends.
 5. The method of claim 4, further comprising: bundlingthe two wire ends together with other lead portions of the same phase asthe two wire ends.
 6. The method of claim 1, wherein winding includeswinding the wire using a winding machine to automatically wind the wirearound the plurality of teeth and route the connection portion(s). 7.The method of claim 1, wherein winding includes winding the wire aroundall the teeth using only one winding needle.
 8. The method of claim 1,further comprising: assembling the stator assembly into a compressorafter winding the wire around the plurality of teeth.
 9. A statorassembly formed by the method of claim
 1. 10. The method of claim 1,wherein: the stator assembly includes a first end cap positioned at afirst one of the ends of the stator assembly and a second end cappositioned at a second one of the ends of the stator assembly; theplurality of teeth include a first tooth, a second tooth, a third tooth,a fourth tooth, a fifth tooth, a sixth tooth, a seventh tooth, an eighthtooth, and a ninth tooth; the first tooth is positioned between theninth tooth and the second tooth, the second tooth is positioned betweenthe first tooth and the third tooth, the third tooth is positionedbetween the second tooth and the fourth tooth, the fourth tooth ispositioned between the third tooth and the fifth tooth, the fifth toothis positioned between the fourth tooth and the sixth tooth, the sixthtooth is positioned between the fifth tooth and the seventh tooth, theseventh tooth is positioned between the sixth tooth and the eighthtooth, the eighth tooth is positioned between the seventh tooth and theninth tooth, and the ninth tooth is positioned between the eighth toothand the first tooth; winding the wire about a first one of the pluralityof teeth includes routing the wire from the first end of the statorassembly to the second end of the stator assembly through a slot betweenthe second tooth and the third tooth to form a lead portion belonging toa first lead bundle, routing the wire along the second end cap to theeighth tooth, and winding the wire about the eighth tooth to form a coilportion about the eighth tooth; routing the wire from the first one ofthe plurality of teeth to the second one of the plurality of teethincludes routing the wire along the second end cap from the eighth toothto a slot between the first tooth and the second tooth, routing the wirethrough the slot between the first tooth and the second tooth twice toform another lead portion belonging to a second lead bundle, and routingthe wire along the second end cap to the seventh tooth, to form aconnection portion between the eighth tooth and the seventh tooth; andwinding the wire about the second one of the plurality of teeth includeswinding the wire about the seventh tooth to form a coil portion aboutthe seventh tooth; the method further comprising routing the wire alongthe second end cap from the seventh tooth to a slot between the ninthtooth and the first tooth, routing the wire through the slot between theninth tooth and the first tooth twice to form another lead portionbelonging to a third lead bundle, routing the wire along the second endcap to the sixth tooth, winding the wire about the sixth tooth, routingthe wire along the second end cap from the sixth tooth to the slotbetween the second tooth and the third tooth, routing the wire throughthe slot between the second tooth and the third tooth twice to formanother lead portion belonging to the first lead bundle, routing thewire along the second end cap to the fifth tooth, winding the wire aboutthe fifth tooth, routing the wire along the second end cap from thefifth tooth to the slot between the first tooth and the second tooth,routing the wire through the slot between the first tooth and the secondtooth twice to form another lead potion belonging to the second leadbundle, routing the wire along the second end cap to the fourth tooth,winding the wire about the fourth tooth, routing the wire along thesecond end cap from the fourth tooth to the slot between the ninth toothand the first tooth, routing the wire through the slot between the ninthtooth and the first tooth twice to form another lead portion belongingto the third lead bundle, routing the wire along the second end cap tothe third tooth, winding the wire about the third tooth, routing thewire along the outside of the first end cap from the third tooth to thesecond tooth to form another lead portion belonging to the first leadbundle, winding the wire about the second tooth, routing the wire alongthe outside of the first end cap from the second tooth to the firsttooth to form another lead portion belonging to the second lead bundle,winding the wire about the first tooth, routing the wire outside of thefirst end cap from the first tooth to the ninth tooth to form anotherlead portion belonging to the third lead bundle, winding the wire aboutthe ninth tooth, and routing the wire along the first end cap from theninth tooth to the slot between the second tooth and the third tooth toform another lead portion belonging to the first lead bundle.
 11. Themethod of claim 1, wherein: the stator assembly includes a first end cappositioned at a first one of the ends of the stator assembly and asecond end cap positioned at a second one of the ends of the statorassembly; the plurality of teeth include a first tooth, a second tooth,a third tooth, a fourth tooth, a fifth tooth, a sixth tooth, a seventhtooth, an eighth tooth, and a ninth tooth; the first tooth is positionedbetween the ninth tooth and the second tooth, the second tooth ispositioned between the first tooth and the third tooth, the third toothis positioned between the second tooth and the fourth tooth, the fourthtooth is positioned between the third tooth and the fifth tooth, thefifth tooth is positioned between the fourth tooth and the sixth tooth,the sixth tooth is positioned between the fifth tooth and the seventhtooth, the seventh tooth is positioned between the sixth tooth and theeighth tooth, the eighth tooth is positioned between the seventh toothand the ninth tooth, and the ninth tooth is positioned between theeighth tooth and the first tooth; winding the wire about a first one ofthe plurality of teeth includes routing the wire from the first end ofthe stator assembly to the second end of the stator assembly through aslot between the third tooth and the fourth tooth to form a lead portionbelonging to a first lead bundle, routing the wire along the second endcap to the ninth tooth, and winding the wire about the ninth tooth toform a coil portion about the ninth tooth; routing the wire from thefirst one of the plurality of teeth to the second one of the pluralityof teeth includes routing the wire along the second end cap from theninth tooth to a slot between the second tooth and the third tooth,routing the wire through the slot between the second tooth and the thirdtooth twice to form another lead portion belonging to a second leadbundle, and routing the wire along the second end cap to the eighttooth, to form a connection portion between the ninth tooth and theeighth tooth; and winding the wire about the second one of the pluralityof teeth includes winding the wire about the eighth tooth to form a coilportion about the eighth tooth; the method further comprising routingthe wire along the second end cap from the eighth tooth to a slotbetween the first tooth and the second tooth, routing the wire throughthe slot between the first tooth and the second tooth twice to formanother lead portion belonging to a third lead bundle, routing the wirealong the second end cap to the seventh tooth, winding the wire aboutthe seventh tooth, routing the wire along the second end cap from theseventh tooth to the slot between the third tooth and the fourth tooth,routing the wire through the slot between the third tooth and the fourthtooth twice to form another lead portion belonging to the first leadbundle, routing the wire along the second end cap to the sixth tooth,winding the wire about the sixth tooth, routing the wire along thesecond end cap from the sixth tooth to the slot between the second toothand the third tooth, routing the wire through the slot between thesecond tooth and the third tooth twice to form another lead potionbelonging to the second lead bundle, routing the wire along the secondend cap to the fifth tooth, winding the wire about the fifth tooth,routing the wire along the second end cap from the fifth tooth to theslot between the first tooth and the second tooth, routing the wirethrough the slot between the first tooth and the second tooth twice toform another lead portion belonging to the third lead bundle, routingthe wire along the second end cap to the fourth tooth, winding the wireabout the fourth tooth, routing the wire along the second end cap fromthe fourth tooth to a slot between the third tooth and the fourth tooth,routing the wire through the slot between the third tooth and the fourthtooth once to form another lead portion belonging to the first leadbundle, winding the wire about the third tooth, routing the wire alongthe second end cap from the third tooth to the second tooth, routing thewire trough the slot between the second tooth and the third tooth onceto form another lead portion belonging to the second lead bundle,winding the wire about the second tooth, routing the wire along thesecond end cap from the second tooth to the slot between the first toothand the second tooth, routing the wire through the slot between thefirst tooth and the second tooth once to form another lead portionbelonging to the third lead bundle, winding the wire about the firsttooth, and routing the wire along the first end cap from the first toothto the slot between the third tooth and the fourth tooth to form anotherlead portion belonging to the first lead bundle.
 12. The method of claim1, wherein: the stator assembly includes a first end cap positioned at afirst one of the ends of the stator assembly and a second end cappositioned at a second one of the ends of the stator assembly; theplurality of teeth include a first tooth, a second tooth, a third tooth,a fourth tooth, a fifth tooth, a sixth tooth, a seventh tooth, an eighthtooth, and a ninth tooth; the first tooth is positioned between theninth tooth and the second tooth, the second tooth is positioned betweenthe first tooth and the third tooth, the third tooth is positionedbetween the second tooth and the fourth tooth, the fourth tooth ispositioned between the third tooth and the fifth tooth, the fifth toothis positioned between the fourth tooth and the sixth tooth, the sixthtooth is positioned between the fifth tooth and the seventh tooth, theseventh tooth is positioned between the sixth tooth and the eighthtooth, the eighth tooth is positioned between the seventh tooth and theninth tooth, and the ninth tooth is positioned between the eighth toothand the first tooth; winding the wire about a first one of the pluralityof teeth includes routing the wire from the first end of the statorassembly to the second end of the stator assembly through a slot betweenthe second tooth and the third tooth to form a lead portion belonging toa first lead bundle, routing the wire along the second end cap to theeighth tooth, and winding the wire about the eighth tooth to form a coilportion about the eighth tooth; routing the wire from the first one ofthe plurality of teeth to the second one of the plurality of teethincludes routing the wire along the second end cap from the eighth toothto a slot between the first tooth and the second tooth, routing the wirethrough the slot between the first tooth and the second tooth twice toform another lead portion belonging to a second lead bundle, and routingthe wire along the second end cap to the seventh tooth, to form aconnection portion between the eighth tooth and the seventh tooth; andwinding the wire about the second one of the plurality of teeth includeswinding the wire about the seventh tooth to form a coil portion aboutthe seventh tooth; the method further comprising routing the wire alongthe second end cap from the seventh tooth to a slot between the ninthtooth and the first tooth, routing the wire through the slot between theninth tooth and the first tooth twice to form another lead portionbelonging to a third lead bundle, routing the wire along the second endcap to the sixth tooth, winding the wire about the sixth tooth, routingthe wire along the second end cap from the sixth tooth to the slotbetween the second tooth and the third tooth, routing the wire throughthe slot between the second tooth and the third tooth twice to formanother lead portion belonging to the first lead bundle, routing thewire along the second end cap to the fifth tooth, winding the wire aboutthe fifth tooth, routing the wire along the second end cap from thefifth tooth to the slot between the first tooth and the second tooth,routing the wire through the slot between the first tooth and the secondtooth twice to form another lead potion belonging to the second leadbundle, routing the wire along the second end cap to the fourth tooth,winding the wire about the fourth tooth, routing the wire along thesecond end cap from the fourth tooth to the slot between the ninth toothand the first tooth, routing the wire through the slot between the ninthtooth and the first tooth twice to form another lead portion belongingto the third lead bundle, routing the wire along the second end cap tothe third tooth, winding the wire about the third tooth, routing thewire along the inside of the first end cap from the third tooth to thesecond tooth to form another lead portion belonging to the first leadbundle, winding the wire about the second tooth, routing the wire alongthe inside of the first end cap from the second tooth to the first toothto form another lead portion belonging to the second lead bundle,winding the wire about the first tooth, routing the wire inside of thefirst end cap from the first tooth to the ninth tooth to form anotherlead portion belonging to the third lead bundle, winding the wire aboutthe ninth tooth, and routing the wire along the first end cap from theninth tooth to the slot between the second tooth and the third tooth toform another lead portion belonging to the first lead bundle.
 13. Themethod of claim 1, wherein: the stator assembly includes a first end cappositioned at a first one of the ends of the stator assembly and asecond end cap positioned at a second one of the ends of the statorassembly; the plurality of teeth include a first tooth, a second tooth,a third tooth, a fourth tooth, a fifth tooth, a sixth tooth, a seventhtooth, an eighth tooth, and a ninth tooth; the first tooth is positionedbetween the ninth tooth and the second tooth, the second tooth ispositioned between the first tooth and the third tooth, the third toothis positioned between the second tooth and the fourth tooth, the fourthtooth is positioned between the third tooth and the fifth tooth, thefifth tooth is positioned between the fourth tooth and the sixth tooth,the sixth tooth is positioned between the fifth tooth and the seventhtooth, the seventh tooth is positioned between the sixth tooth and theeighth tooth, the eighth tooth is positioned between the seventh toothand the ninth tooth, and the ninth tooth is positioned between theeighth tooth and the first tooth; winding the wire about a first one ofthe plurality of teeth includes routing the wire from the first end ofthe stator assembly to the second end of the stator assembly through aslot between the third tooth and the fourth tooth to form a leadportion, routing the wire along the second end cap to the ninth tooth,and winding the wire about the ninth tooth to form a coil portion aboutthe ninth tooth; routing the wire from the first one of the plurality ofteeth to the second one of the plurality of teeth includes routing thewire along the second end cap from the ninth tooth to a slot between thesecond tooth and the third tooth, routing the wire through the slotbetween the second tooth and the third tooth twice to form another leadportion, and routing the wire along the second end cap to the eighthtooth, to form a connection portion between the ninth tooth and theeighth tooth; and winding the wire about the second one of the pluralityof teeth includes winding the wire about the eighth tooth to form a coilportion about the eighth tooth; the method further comprising routingthe wire along the second end cap from the eighth tooth to a slotbetween the first tooth and the second tooth, routing the wire throughthe slot between the first tooth and the second tooth twice to formanother lead portion, routing the wire along the second end cap to theseventh tooth, winding the wire about the seventh tooth, routing thewire along the second end cap from the seventh tooth to the slot betweenthe sixth tooth and the seventh tooth, routing the wire through the slotbetween the sixth tooth and the seventh tooth once to form another leadportion, winding the wire about the sixth tooth, routing the wire alongthe second end cap from the sixth tooth to the slot between the fifthtooth and the sixth tooth, routing the wire through the slot between thefifth tooth and the sixth tooth once to form another lead potion,winding the wire about the fifth tooth, routing the wire along thesecond end cap from the fifth tooth to the slot between the fourth toothand the fifth tooth, routing the wire through the slot between thefourth tooth and the fifth tooth once to form another lead portion,winding the wire about the fourth tooth, routing the wire along thesecond end cap from the fourth tooth to the slot between the third toothand the fourth tooth, routing the wire through the slot between thethird tooth and the fourth tooth to form another lead portion, windingthe wire about the third tooth, routing the wire along the second endcap from the third tooth to slot between the second tooth and the thirdtooth, routing the wire through the slot between the second tooth andthe third tooth once to form another lead portion, winding the wireabout the second tooth, routing the wire along the second end cap fromthe second tooth to the slot between the first tooth and the secondtooth, routing the wire through the slot between the first and secondtooth once to form another lead portion, winding the wire about thefirst tooth, and routing the wire along the first end cap from the firsttooth to the slot between the third tooth and the forth tooth to formanother lead portion.